Fiber-Optic Strength Member Components for Use in Outer Strength Member Layers

ABSTRACT

A cable containing at least one optical fiber in a strength member and methods for manufacturing the strength member and cable are provided. A cable may include a cable core and armor wire strength members that surround the cable core. One of the armor wire strength members that surround the cable core contains an optical fiber.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of and claims priority to U.S. patent application Ser. No. 15/686,326, filed Aug. 25, 2017, which is incorporated herein by reference.

BACKGROUND

This disclosure relates to systems and methods for protecting an optical fiber within a downhole cable, seismic cable, or other cable, while reducing a loss of signal quality on the optical fiber.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as an admission of any kind.

Producing hydrocarbons from a wellbore drilled into a geological formation is a remarkably complex endeavor. In many cases, decisions involved in hydrocarbon exploration and production may be informed by measurements from downhole well-logging tools that are conveyed deep into the wellbore. The measurements may be used to infer properties and characteristics of the geological formation surrounding the wellbore. Thus, when a wellbore is investigated to determine the physical condition of a fluid within the wellbore, a gas within the wellbore, or the wellbore itself, it may be desirable to place a cable with associated measurement tools and/or sensors within the wellbore.

Such measurement tools and/or sensors may include one or more optical fibers, which may provide high-speed electromagnetic interference (EMI) immune telemetry to a data processing system coupled to the end of the cable. To reduce a chance of potential damage to the optical fibers, the one or more optical fibers may be housed within protective structures in the cable core. Such protection may result in a loss of signal quality from the optical fibers, however, since the cable core is relatively isolated from changes in the wellbore environment due to armor wire strength members which surround and/or protect the cable core.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In one example, a cable includes a cable core and a number of armor wire strength members that surround the cable core. A first armor wire strength member of the armor wire strength members includes a first optical fiber.

In another example, a method includes inserting a first optical fiber into a space shaped into one or more wires, enclosing the space to enclose the first optical fiber in an optical-fiber-containing structure, and extruding a first polymer tube over the optical-fiber-containing structure.

In another example, a cable includes a first group of wire members and a second group of wire members disposed circumferentially around a center of the cable. The first group may be a first radial distance from the center of the cable and the second group may be a second, farther, radial distance from the center of the cable. A first wire member of the second group of wire strength members contains a first optical fiber.

Various refinements of the features noted above may be undertaken in relation to various aspects of the present disclosure. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. The brief summary presented above is intended to familiarize the reader with certain aspects and contexts of embodiments of the present disclosure without limitation to the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a schematic diagram of a wellbore logging system and cable that may obtain data measurements along the length of the wellbore, in accordance with an embodiment of the present disclosure;

FIG. 2a is a cross-sectional view of the cable of FIG. 1, which illustrates an optical fiber cable contained within an optical-fiber-containing armor wire strength member that surrounds a cable core, in accordance with an embodiment of the present disclosure;

FIG. 2b is a cross-sectional view of a marine cable, which illustrates the optical fiber cable contained within the optical-fiber-containing armor wire strength member that surrounds a marine cable core, in accordance with an embodiment of the present disclosure;

FIG. 3 is a method of manufacturing an optical-fiber-containing circular structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 4 is a cross-sectional view of the optical-fiber-containing circular structure, in accordance with an embodiment of the present disclosure;

FIG. 5 is a cross-sectional view of an optical-fiber-containing circular structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 6 is a cross-sectional view of an optical-fiber-containing circular structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 7 is a cross-sectional view of an optical-fiber-containing circular structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 8 is a cross-sectional view of the optical-fiber-containing circular structure of FIG. 5 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 9 is a cross-sectional view of the optical-fiber-containing circular structure of FIG. 6 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 10 is a cross-sectional view of the optical-fiber-containing circular structure of FIG. 7 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 11 is a method of manufacturing an optical-fiber-containing grooved structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 12 is a cross-sectional view of the optical-fiber-containing grooved structure, in accordance with an embodiment of the present disclosure;

FIG. 13 is a cross-sectional view of an optical-fiber-containing grooved structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 14 is a cross-sectional view of an optical-fiber-containing grooved structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 15 is a cross-sectional view of an optical-fiber-containing grooved structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 16 is a cross-sectional view of the optical-fiber-containing grooved structure of FIG. 13 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 17 is a cross-sectional view of the optical-fiber-containing grooved structure of FIG. 14 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 18 is a cross-sectional view of the optical-fiber-containing grooved structure of FIG. 15 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 19 is a method of manufacturing an optical-fiber-containing C-shaped structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 20 is a cross-sectional view of the optical-fiber-containing C-shaped structure, in accordance with an embodiment of the present disclosure;

FIG. 21 is a cross-sectional view of an optical-fiber-containing C-shaped structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 22 is a cross-sectional view of an optical-fiber-containing C-shaped structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 23 is a cross-sectional view of an optical-fiber-containing C-shaped structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 24 is a cross-sectional view of the optical-fiber-containing C-shaped structure of FIG. 21 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 25 is a cross-sectional view of the optical-fiber-containing C-shaped structure of FIG. 22 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 26 is a cross-sectional view of the optical-fiber-containing C-shaped structure of FIG. 23 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 27 is a method of manufacturing an optical-fiber-containing multichannel structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 28 is a cross-sectional view of the optical-fiber-containing multichannel structure, in accordance with an embodiment of the present disclosure;

FIG. 29 is a cross-sectional view of an optical-fiber-containing multichannel structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 30 is a cross-sectional view of an optical-fiber-containing multichannel structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 31 is a cross-sectional view of an optical-fiber-containing multichannel structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 32 is a cross-sectional view of the optical-fiber-containing multichannel structure of FIG. 29 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 33 is a cross-sectional view of the optical-fiber-containing multichannel structure of FIG. 30 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 34 is a cross-sectional view of the optical-fiber-containing multichannel structure of FIG. 31 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 35 is a method of manufacturing an optical-fiber-containing capped structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 36 is a cross-sectional view of the optical-fiber-containing capped structure described in FIG. 35, in accordance with an embodiment of the present disclosure;

FIG. 37 is a cross-sectional view of an optical-fiber-containing capped structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 38 is a cross-sectional view of an optical-fiber-containing capped structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 39 is a cross-sectional view of an optical-fiber-containing capped structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 40 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 37 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 41 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 38 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 42 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 39 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 43 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 37 that includes an adhesive bonded cap piece, in accordance with an embodiment of the present disclosure;

FIG. 44 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 38 that includes an adhesive bonded cap piece, in accordance with an embodiment of the present disclosure;

FIG. 45 is a cross-sectional view of the optical-fiber-containing capped structure of FIG. 39 that includes an adhesive bonded cap piece, in accordance with an embodiment of the present disclosure;

FIG. 46 is a method of manufacturing an optical-fiber-containing plugged structure of the optical-fiber-containing armor wire strength member, in accordance with an embodiment of the present disclosure;

FIG. 47 is a cross-sectional view of the optical-fiber-containing plugged structure described in FIG. 46, in accordance with an embodiment of the present disclosure;

FIG. 48 is a cross-sectional view of an optical-fiber-containing plugged structure that includes air as filler material, in accordance with an embodiment of the present disclosure;

FIG. 49 is a cross-sectional view of an optical-fiber-containing plugged structure that includes a silicon polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 50 is a cross-sectional view of an optical-fiber-containing plugged structure that includes a UV-curable polymer as filler material, in accordance with an embodiment of the present disclosure;

FIG. 51 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 48 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 52 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 49 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 53 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 50 that includes an exterior polymer layer, in accordance with an embodiment of the present disclosure;

FIG. 54 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 48 that includes a crimped plug wire, in accordance with an embodiment of the present disclosure;

FIG. 55 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 49 that includes a crimped plug wire, in accordance with an embodiment of the present disclosure;

FIG. 56 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 50, a crimped plug wire, in accordance with an embodiment of the present disclosure;

FIG. 57 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 48 that includes a welded plug wire, in accordance with an embodiment of the present disclosure;

FIG. 58 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 49 that includes a welded plug wire, in accordance with an embodiment of the present disclosure;

FIG. 59 is a cross-sectional view of the optical-fiber-containing plugged structure of FIG. 50 that includes a welded plug wire, in accordance with an embodiment of the present disclosure;

FIG. 60 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing circular structure of FIG. 8 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 61 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing grooved structure of FIG. 16 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 62 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing C-shaped structure of FIG. 24 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 63 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing multichannel structure of FIG. 32 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 64 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing capped structure of FIG. 40 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 65 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing plugged structure of FIG. 51 encased by a snug fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 66 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing circular structure of FIG. 8 encased a loose-fitting exterior metallic tube, in accordance with an embodiment of the present disclosure;

FIG. 67 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing circular structure of FIG. 8 encased by a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 68 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing grooved structure of FIG. 16 encased by a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 69 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing C-shaped structure of FIG. 24 encased by a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 70 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing multichannel structure of FIG. 32 encased by a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 71 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing capped structure of FIG. 40 encased by a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 72 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing plugged structure of FIG. 51 encased a polymer jacket, in accordance with an embodiment of the present disclosure;

FIG. 73 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing circular structure of FIG. 8 encased by a served wire jacket, in accordance with an embodiment of the present disclosure;

FIG. 74 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing grooved structure of FIG. 16 encased by a served wire jacket, in accordance with an embodiment of the present disclosure;

FIG. 75 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing C-shaped structure of FIG. 24 encased by a served wire jacket, in accordance with an embodiment of the present disclosure;

FIG. 76 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing multichannel structure of FIG. 32 encased by a served wire jacket, in accordance with an embodiment of the present disclosure;

FIG. 77 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing capped structure of FIG. 40 encased by a served wire jacket, in accordance with an embodiment of the present disclosure; and

FIG. 78 is a cross-sectional view of an optical-fiber-containing armor wire strength member that includes the optical-fiber-containing plugged structure of FIG. 51 encased by a served wire jacket, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would still be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

With this in mind, FIG. 1 illustrates a well-logging system 10 that may employ the systems and methods of this disclosure. The well-logging system 10 may be used to convey a downhole tool 12 or other weight through a geological formation 14 via a wellbore 16. The downhole tool 12 may be conveyed on a cable 18 via a logging winch system 20. Although the logging winch system 20 is schematically shown in FIG. 1 as a mobile logging winch system carried by a truck, the logging winch system 20 may be substantially fixed (e.g., a long-term installation that is substantially permanent or modular). Any suitable cable 18 for well logging may be used. The cable 18 may be spooled and unspooled on a drum 22 and an auxiliary power source 24 may provide energy to the logging winch system 20 and/or the downhole tool 12.

The cable 18 may additionally contain one or more optical fibers embedded within the cable core or armor wire strength members of the cable 18, which may collect data (e.g., such as temperature, pressure, strain, seismic activity, or other desired parameters) regarding the interior condition of the wellbore 16. The one or more optical fibers may transmit the data to the logging winch system 20.

The downhole tool 12 and/or cable 18 may provide logging measurements 26 to a data processing system 28 via any suitable telemetry (e.g., via electrical signals pulsed through the geological formation 14 or via mud pulse telemetry). The data processing system 28 may process the logging measurements 26 which may indicate certain properties of the wellbore 16 (e.g., temperature, pressure, strain, seismic activity, or other desired parameters) that might otherwise be indiscernible by a human operator.

To this end, the data processing system 28 thus may be any electronic data processing system that can be used to carry out the systems and methods of this disclosure. For example, the data processing system 28 may include a processor 30, which may execute instructions stored in memory 32 and/or storage 34. As such, the memory 32 and/or the storage 34 of the data processing system 28 may be any suitable article of manufacture that can store the instructions. The memory 32 and/or the storage 34 may be ROM memory, random-access memory (RAM), flash memory, an optical storage medium, or a hard disk drive, to name a few examples. A display 36, which may be any suitable electronic display, may provide a visualization, a well log, or other indication of properties in the geological formation 14 or the wellbore 16 using the logging measurements 26.

FIG. 2a is a cross-sectional view of one embodiment of the cable 18. The cable 18 may house a cable core 40, which may be circumferentially surrounded by one or more armor wire strength members 42. The armor wire strength members 42 may be served (e.g., coiled helically) around the cable core 40, extend longitudinally along the length of the cable core 40, or be disposed about the cable core 40 in any fashion suitable to surround the cable core 40. The armor wire strength members 42 may physically protect the cable core 40 and may provide additional rigidity to the cable 18. In addition, the armor wire strength members 42 may support the weight of the cable 18 and alleviate strain on the cable core 40.

The cable core 40 may include one or more signal cables 44. The signal cables 44 may include internal wires 46 disposed within protective structures 48. The internal wires 46 may include sensors (e.g., one or more optical fibers 50), copper wires, or any other suitable wires desired within the cable 18. The internal wires 46 may transmit instructional signals or electrical power to a component coupled to the end of the cable 18 (e.g., the downhole tool 12). The one or more optical fibers 50 within the cable core 40 may sense internal conditions of the wellbore 16 and relay data regarding the internal conditions to the data processing system 28. The protective structures 48 may encase the internal wires 46 and physically protect the internal wires during operation of the cable 18. Although the one or more optical fibers 50 may be less susceptible to physical damage when housed in the cable core 40, the signal quality of the one or more optical fibers 50 may be diminished in such a configuration. To achieve a better signal to noise ratio in regard to the parameters being monitored (e.g., temperature, pressure, seismic profiling, or others), the one or more optical fibers 50 may be located near the outside perimeter of the cable 18. By disposing the one or more optical fibers 50 within one or more optical-fiber-containing armor wire strength members 52, the one or more optical fibers 50 may be disposed about the perimeter of the cable 18 while still receiving physical protection through the optical-fiber-containing armor wire strength members 52. The optical-fiber-containing armor wire strength members 52 may additionally be disposed within the cable core 40 of the cable 18. Each optical-fiber-containing armor wire strength member 52 may house an optical-fiber-containing structure 54 that includes the one or more optical fibers 50. The optical-fiber-containing structure 54 may be circumferentially encased by a thin polymer layer 56. The thin polymer layer 56 may additionally be encased by a protective shield 58 (e.g., seam welded tube, thick polymer layer, metallic wires).

FIG. 2b is a cross sectional view of a marine cable 55. The marine cable 55 may include the cable core 40. The cable core 40 may include the one or more signal cables 44. The signal cables 44 may include the internal wires 46 disposed within the protective structures 48. The internal wires 46 may include the sensors (e.g., the one or more optical fibers 50), copper wires, or any other suitable wires desired within the marine cable 55. The internal wires 46 may transmit instructional signals or electrical power to a component coupled to the end of the marine cable 55 (e.g., the downhole tool 12). The protective structures 48 may encase the internal wires 46 and physically protect the internal wires during operation of the marine cable 55. Although the one or more optical fibers 50 may be less susceptible to physical damage when housed in the cable core 40, the signal quality of the one or more optical fibers 50 may be diminished in such a configuration. To achieve a better signal to noise ratio in regard to the parameters being monitored (e.g., temperature, pressure, seismic profiling, or others), the one or more optical fibers 50 may be located near the outside perimeter of the marine cable 55. By disposing the one or more optical fibers 50 within the one or more optical-fiber-containing armor wire strength members 52, the one or more optical fibers 50 may be disposed about the perimeter of the marine cable 55 while still receiving physical protection through the optical-fiber-containing armor wire strength members 52. The optical-fiber-containing armor wire strength members 52 may be disposed within a shielding layer 57 of the marine cable 55. The shielding layer 57 may additionally be encased by a protective outer layer 59. The optical-fiber-containing armor wire strength members 52 may additionally be disposed within the cable core 40 of the marine cable 55.

FIGS. 3-78 illustrate various methods of assembly and/or embodiments of the optical-fiber-containing structure 54 of the optical-fiber-containing armor wire strength members 52. FIG. 3 is a method 60 of assembly for an optical-fiber-containing circular structure 54 a of the optical-fiber-containing armor wire strength members 52. The optical-fiber-containing circular structure 54 a and various embodiments thereof are shown in FIGS. 5-10. Block 64 relates to FIG. 4. The optical-fiber-containing circular structure 54 a may include two semicircular (or more than two partially circular) profile steel wires 62, which encase the one or more optical fibers 50. The example of FIGS. 3-10 show two semicircular profile steel wires 62 of substantially equal dimensions, but in some embodiments, one of these may cover greater than a half-circle and another less than a half-circle. In other embodiments, more than two steel wires 62 may have partially semicircular profiles that collectively form a circular shape. In still other embodiments, the steel wires 62 may form a non-circular or oval shape. For the sake of brevity, the steel wires 62 are discussed as being semicircular, but it should be appreciated that any suitable dimensions are contemplated by this disclosure. The semicircular profile steel wires 62 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 5-7, which relate to block 66 of FIG. 3, when the two semicircular profile steel wires 62 encase the one or more optical fibers 50, a gap 68 may form between them. The gap 68 may remain empty (e.g., filled with air 70), filled with a soft silicone polymer 72, or filled with a UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIGS. 5-7, respectively. Additionally or alternatively, the gap 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed between the two semicircular profile steel wires 62.

Turning now to FIGS. 8-10, which relate to block 67 of FIG. 3, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing circular structure 54 a depicted in FIGS. 5-7, as shown in FIGS. 8-10 respectively. The thin polymer layer 56 may encase the optical-fiber-containing circular structure 54 a to maintain the position of the semicircular profile steel wires 62. In another embodiment, the semicircular profile steel wires 62 may be bonded together via an adhesive (e.g., bonding glue, welding, or other) before being encased by the thin polymer layer 56.

FIG. 11 is a method 90 of assembly for an optical-fiber-containing grooved structure 54 b of the optical-fiber-containing armor wire strength member 52. The optical-fiber-containing grooved structure 54 b and various embodiments thereof are shown in FIGS. 13-18. Block 96 relates to FIG. 12. The optical-fiber-containing grooved structure 54 b may include a steel wire 92, in which a longitudinal channel 94 may extend along the length of the steel wire 92. The one or more optical fibers 50 may be disposed within the longitudinal channel 94 of the steel wire 92. The steel wire 92 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 13-15, which relate to block 98 of FIG. 11, when the one or more optical fibers 50 are disposed within the longitudinal channel 94, the gap 68 may form between them. The gap 68 may remain empty (e.g., filled with air 70), filled with the soft silicone polymer 72, or filled with the UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIGS. 13-15 respectively. Additionally or alternatively, the gap 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed within the longitudinal channel 94 of the optical-fiber-containing grooved structure 54 b.

Turning now to FIGS. 16-18, which relate to block 100 of FIG. 11, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing grooved structure 54 b depicted in FIGS. 13-15, as shown in FIGS. 16-18 respectively. The thin polymer layer 56 may encase the optical-fiber-containing grooved structure 54 b to maintain the position of the one or more optical fibers 50 within the longitudinal channel 94 of the optical-fiber-containing grooved structure 54 b.

FIG. 19 is a method 110 of assembly for an optical-fiber-containing C-shaped structure 54 c of the optical-fiber-containing armor wire strength member 52. The optical-fiber-containing C-shaped structure 54 c and various embodiments thereof are shown in FIGS. 21-26. Block 116 relates to FIG. 20. The optical-fiber-containing C-shaped structure 54 c may include a shaped steel wire 112, in which a hollow region 114 extends longitudinally along the length of the shaped steel wire 112. The one or more optical fibers 50 may be disposed within the hollow region 114 of the shaped steel wire 112. The shaped steel wire 112 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 21-23, which relate to block 118 of FIG. 19, when the one or more optical fibers 50 are disposed within the hollow region 114, the gap 68 may form between them. The gap 68 may remain empty (e.g., filled with air 70), filled with the soft silicone polymer 72, or filled with the UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIG. 21-23 respectively. Additionally or alternatively, the gap 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed within the hollow region 114 of the shaped steel wire 112.

Turning now to FIGS. 24-26, which relate to block 120 of FIG. 19, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing C-shaped structure 54 c depicted in FIGS. 21-23, as shown in FIGS. 24-26 respectively. The thin polymer layer 56 may encase the optical-fiber-containing C-shaped structure 54 c to maintain the position of the one or more optical fibers 50 within the hollow region 114 or the optical-fiber-containing C-shaped structure 54 c.

FIG. 27 is a method 130 of assembly for an optical-fiber-containing multichannel structure 54 d of the optical-fiber-containing armor wire strength members 52. The optical-fiber-containing multichannel structure 54 d and various embodiments thereof are shown in FIGS. 29-34. Block 132 relates to FIG. 28. The optical-fiber-containing multichannel strength structure 54 d may include a channeled steel wire 134, wherein channels 136 extend longitudinally along the length of the channeled steel wire 134. Although three channels 136 are shown in the illustrated embodiment, the channeled steel wire 134 may include 1, 2, 3, 4, 5, or more channels 136. The one or more optical fibers 50 may be disposed within the channels 136 of the channeled steel wire 134. The channeled steel wire 134 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 29-31, which relate to block 138 of FIG. 27, when the one or more optical fibers 50 are disposed within the channels 136, gaps 68 may form between them. The gaps 68 may remain empty (e.g., filled with air 70), filled with the soft silicone polymer 72, or filled with the UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIG. 29-31 respectively. Additionally or alternatively, the gaps 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed within the channels 136 of the optical-fiber-containing multichannel structure 54 d.

Turning now to FIGS. 32-34, which relate to block 140 of FIG. 27, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing multichannel structure 54 d depicted in FIGS. 29-31, as shown in FIGS. 32-34 respectively. The thin polymer layer 56 may encase the optical-fiber-containing multichannel structure 54 d to maintain the position of the one or more optical fibers 50 within the channels 136 or the optical-fiber-containing multichannel structure 54 d.

FIG. 35 is a method 150 of assembly for an optical-fiber-containing capped structure 54 e of the optical-fiber-containing armor wire strength members 52. The optical-fiber-containing capped structure 54 e, and various embodiments thereof, are shown in FIGS. 37-45. Block 152 relates to FIG. 36. The optical-fiber-containing capped structure 54 e may include a cap piece 154 and a channeled steel wire 156, in which a channel 158 extends longitudinally along the length of the channeled steel wire 156. The one or more optical fibers 50 may be disposed within the channel 158 of the channeled steel wire 156. The cap piece 154 may subsequently be coupled to the channeled steel wire 156. The cap piece 154 and/or the channeled steel wire 156 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 37-39, which relate to block 160 of FIG. 35, when the one or more optical fibers 50 are disposed within the channel 158, the gap 68 may form between them. The gap 68 may remain empty (e.g., filled with air 70), filled with the soft silicone polymer 72, or filled with the UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIG. 37-39 respectively. Additionally or alternatively, the gap 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed within the channel 158 of the optical-fiber-containing capped strength member 54 e. After the desired filler material is applied, the cap piece 154 may be disposed upon the channeled steel wire 156 to encapsulate the one or more optical fibers 50.

Turning now to FIGS. 40-42, which relate to block 162 of FIG. 35, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing capped structure 54 e depicted in FIGS. 37-39, as shown in FIGS. 40-42 respectively. The thin polymer layer 56 may encase the optical-fiber-containing capped strength structure 54 e to maintain the position of cap piece 154 in relation to the channeled steel wire 156.

Turning now to FIGS. 43-45, showing additional embodiments of the optical-fiber-containing capped structure 54 e shown in FIGS. 37-39 respectively, the cap piece 154 may be coupled directly to the channeled steel wire 156 via an adhesive 164 (e.g., bonding glue, welding, or other) as shown in FIGS. 43-45. In this embodiment, the thin polymer layer 56 is obsolete, such that the overall size of the optical-fiber-containing capped structure 54 e may be decreased.

FIG. 46 is a method 170 of assembly for an optical-fiber-containing plugged structure 54 f of the optical-fiber-containing armor wire strength member 52. The optical-fiber-containing plugged structure 54 f, and various embodiments thereof, is shown in FIGS. 48-59. Block 172 relates to FIG. 47. The optical-fiber-containing plugged structure 54 f may include a plug wire 174 and a receptor wire 176, in which a channel 178 extends longitudinally along the length of the receptor wire 176. The receptor wire 176 may include an upper end portion 156 which may house the plug wire 174 and a lower end portion 182 which may house the one or more optical fibers 50. The one or more optical fibers 50 may be placed within the lower end portion 182 of the receptor wire 176 and the plug wire 174 may be placed within the upper end portion 156 of the receptor wire 176, such that the plug wire 174 and receptor wire 176 may encapsulate the one or more optical fibers 50. The receptor wire 176 may include a flat section 184, which may facilitate manufacturing of the embodiment. The plug wire 174 and/or the receptor wire 176 may include galvanized improved plow steel, stainless steel, high carbon steel, or any suitable alloy.

Turning now to FIGS. 48-50, which relate to block 186 of FIG. 46, when the one or more optical fibers 50 are disposed within the channel 178, the gap 68 may form between them. The gap 68 may remain empty (e.g., filled with air 70), filled with the soft silicone polymer 72, or filled with the UV-curable polymer 74 that may be hardened using UV-radiation 76, as shown by FIG. 48-50 respectively. Additionally or alternatively, the gap 68 may be filled with any other suitable filler material. The one or more optical fibers 50 may be encased by a filler material (e.g., air 70, soft silicone polymer 72, UV-curable polymer 74) before being disposed within the channel 178 of the optical-fiber-containing plugged structure 54 f After the desired filler is applied, the plug wire 174 may be disposed upon the upper end portion 156 of the receptor wire 176 to encapsulate the one or more optical fibers 50.

Turning now to FIGS. 51-53, which relate to block 188 of FIG. 46, the thin polymer layer 56 may be extruded over the embodiments of the optical-fiber-containing plugged structure 54 f depicted in FIGS. 48-50, as shown in FIGS. 51-53 respectively. The thin polymer layer 56 may encase the optical-fiber-containing plugged structure 54 f to maintain the position of plug wire 174 in relation to the receptor wire 176.

Turning now to FIGS. 54-56, showing additional embodiments of the optical-fiber-containing plugged structure 54 f shown in FIGS. 48-50 respectively, the plug wire 174 may be press fit into the receptor wire 176 via a crimping force 190. The crimping force 190 may compresses the upper end portion 156 of the channel 178 within the receptor wire 176, such that the plug wire 174 may be permanently coupled to the receptor wire 176. In this embodiment, the thin polymer layer 56 may be obsolete, such that the overall size of the optical-fiber-containing plugged structure 54 f may be decreased.

Turning now to FIGS. 57-59, showing additional embodiments of the optical-fiber-containing plugged structure 54 f shown in FIGS. 48-50 respectively. The plug wire 174 may be directly coupled to the receptor wire 176 via an adhesive 192 (e.g., welding, bonding glue, or other). In this embodiment, the thin polymer layer 56 is obsolete, such that the overall size of the optical-fiber-containing plugged structure 54 f may be decreased.

Turning now to FIGS. 60-65, showing various embodiments of the optical-fiber-containing armor wire strength members 52 of FIG. 2 (52 a, 52 b, 52 c, 52 d, 52 e, 52 f respectively). Supplementary support structures may be coupled with the optical-fiber-containing structures 54 to provide additional strength, protection, and/or rigidity to the various embodiments of the optical-fiber-containing structures 54. FIGS. 60-65 relate to embodiments of the optical-fiber-containing circular structure 54 a, optical-fiber-containing grooved structure 54 b, optical-fiber-containing C-shaped structure 54 c, optical-fiber-containing multichannel structure 54 d, optical-fiber-containing capped structure 54 e, and optical-fiber-containing plugged structure 54 f respectively. Each embodiment may be encased by the thin polymer layer 56. In addition, the thin polymer layer 56 of each embodiment may be circumferentially enclosed by a seam welded tube 58 a, which may fit tightly about the thin polymer layer 56. The seam welded tube 58 a may physically protect the thin polymer layer 56, the optical-fiber-containing structure 54, and/or the one or more optical fibers 50 disposed within the seam welded tube 58 a.

Turning now to FIG. 66, showing another embodiment of the optical-fiber-containing armor wire strength member 52 g. In this embodiment, the seam welded tube 58 a may be loosely disposed about the thin polymer layer 56 and the optical-fiber-containing circular strength structure 54 a. An annular gap 202 may exist between the seam welded tube 58 a and the thin polymer layer 56. Although the embodiment shown composes the optical-fiber-containing circular structure 54 a, the seam welded tube 58 a may also be disposed loosely about any other embodiment of the core 54, such as the optical-fiber-containing grooved structure 54 b, optical-fiber-containing C-shaped structure 54 c, optical-fiber-containing multichannel structure 54 d, optical-fiber-containing capped structure 54 e, optical-fiber-containing plugged structure 54 f, or others.

Turning now to FIGS. 67-72, showing various embodiments of the optical-fiber-containing armor wire strength members 52 of FIG. 2 (52 h, 52 i, 52 j, 52 k, 52 l, 52 m respectively). Supplementary support structures may be coupled with the optical-fiber-containing structures 54 to provide additional strength, protection, and/or rigidity to the various embodiments of the optical-fiber-containing structures 54. FIGS. 67-72 relate to embodiments of the optical-fiber-containing circular structure 54 a, optical-fiber-containing grooved structure 54 b, optical-fiber-containing C-shaped structure 54 c, optical-fiber-containing multichannel structure 54 d, optical-fiber-containing capped structure 54 e, and optical-fiber-containing plugged structure 54 f respectively. Each embodiment may be encased by a thin polymer layer 56. In addition, the thin polymer layer 56 of each embodiment may be circumferentially enclosed by a thick polymer jacket 58 b. The thick polymer jacket 58 b may be compression-extruded over the thin polymer layer 56 of the various embodiments. The thick polymer jacket 58 b may physically protect the thin polymer layer 56, optical-fiber-containing structure 54, and/or the one or more optical fibers 50 disposed within the thick polymer jacket 58 b.

Turning now to FIGS. 73-78, showing various embodiments of the optical-fiber-containing armor wire strength members 52 of FIG. 2 (52 n, 52 o, 52 p, 52 q, 52 r, 52 s respectively). Supplementary support structures may be coupled with the core 54 to provide additional strength, protection, and/or rigidity to the various embodiments of the optical-fiber-containing structure 54. FIGS. 73-78 relate to embodiments of the optical-fiber-containing circular structure 54 a, optical-fiber-containing grooved structure 54 b, optical-fiber-containing C-shaped structure 54 c, optical-fiber-containing multichannel structure 54 d, optical-fiber-containing capped structure 54 e, and optical-fiber-containing plugged structure 54 f respectively. Each embodiment may be encased by a thin polymer layer 56. In addition, the thin polymer layer 56 of each embodiment may be circumferentially enclosed by one or more metallic wires 58 c (e.g., wire jacket). The metallic wires 58 c may be served (e.g., cabled helically) over the thin polymer layer 56. In another embodiment, the metallic wires 58 c may extend longitudinally along the exterior surface of the thin polymer layer 56, or in any suitable fashion to cover the exterior surface of the thin polymer layer 56. The metallic wires 58 c may physically protect the thin polymer layer 56, optical-fiber-containing structure 54, and/or the one or more optical fibers 50 disposed within the casing of metallic wires 58 c.

The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. The disclosed embodiments are suitable for any cable application requiring optical fiber sensors near the outer circumference of a cable, such as wireline cables, wireline cables with partially for fully jacketed strength members, and marine seismic cables. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure. 

1. A method comprising: inserting a first optical fiber into a space shaped into one or more wires; enclosing the space to enclose the first optical fiber in an optical-fiber-containing structure; and extruding a first polymer tube over the optical-fiber-containing structure.
 2. The method of claim 1, wherein inserting the first optical fiber into the space comprises: inserting the first optical fiber between two semi-circular shaped wires; inserting the first optical fiber into a longitudinal channel of a grooved wire; inserting the first optical fiber into a hollow region of a C-shaped wire; or inserting the first optical fiber into one of a plurality of circumferentially spaced channels in a wire; or some combination thereof.
 3. The method of claim 1, comprising filling the space with a material, wherein the material comprises air, a silicon polymer, or a UV-curable polymer, or some combination thereof.
 4. The method of claim 1, comprising extruding a second polymer tube over the first polymer tube to provide additional rigidity or wrapping a plurality of wires over the first polymer tube to provide additional rigidity, or a combination thereof.
 5. The method of claim 1, comprising cabling the optical-fiber-containing structure around a cable core in a cable suitable for use downhole in a wellbore. 